ENGINE COOLING SYSTEM B ENGINE CO A - PDF...

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ENGINE COOLING SYSTEM

B ENGINE

CONTENTS

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SECTION COA

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Revision: 2005 August 2005 Murano

ENGINE COOLING SYSTEM

PRECAUTIONS .......................................................... 2Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TEN-SIONER” .................................................................. 2Precautions for Liquid Gasket .................................. 2

REMOVAL OF LIQUID GASKET SEALING .......... 2LIQUID GASKET APPLICATION PROCEDURE ..... 2

PREPARATION ........................................................... 4Special Service Tools ............................................... 4Commercial Service Tools ........................................ 4

OVERHEATING CAUSE ANALYSIS .......................... 5Troubleshooting Chart .............................................. 5

COOLING SYSTEM .................................................... 7Cooling Circuit .......................................................... 7System Chart ........................................................... 8

ENGINE COOLANT .................................................... 9Inspection ................................................................. 9

LEVEL CHECK ..................................................... 9LEAK CHECK ....................................................... 9

Changing Engine Coolant ........................................ 9DRAINING ENGINE COOLANT ........................... 9REFILLING ENGINE COOLANT ........................ 10FLUSHING COOLING SYSTEM ..........................11

RADIATOR ................................................................ 13Removal and Installation ........................................ 13

REMOVAL ........................................................... 13INSTALLATION ................................................... 14INSPECTION AFTER INSTALLATION ............... 14

Checking Radiator Cap .......................................... 15Checking Radiator .................................................. 15

RADIATOR (ALUMINUM TYPE) .............................. 16Disassembly and Assembly ................................... 16

PREPARATION ................................................... 16DISASSEMBLY ................................................... 16ASSEMBLY ......................................................... 17INSPECTION ...................................................... 19

COOLING FAN .......................................................... 20Removal and Installation ........................................ 20

REMOVAL ........................................................... 20INSTALLATION ................................................... 20INSPECTION AFTER INSTALLATION ................ 20

Disassembly and Assembly .................................... 21DISASSEMBLY ................................................... 21INSPECTION AFTER DISASSEMBLY ................ 21ASSEMBLY ......................................................... 21

WATER PUMP .......................................................... 22Removal and Installation ........................................ 22

REMOVAL ........................................................... 22INSPECTION AFTER REMOVAL ....................... 24INSTALLATION ................................................... 24INSPECTION AFTER INSTALLATION ................ 26

WATER INLET AND THERMOSTAT ASSEMBLY .... 27Removal and Installation ........................................ 27

REMOVAL ........................................................... 27INSPECTION AFTER REMOVAL ....................... 28INSTALLATION ................................................... 28INSPECTION AFTER INSTALLATION ................ 28

WATER OUTLET AND WATER PIPING ................... 29Removal and Installation ........................................ 29

REMOVAL ........................................................... 29INSTALLATION ................................................... 30INSPECTION AFTER INSTALLATION ................ 30

SERVICE DATA AND SPECIFICATIONS (SDS) ...... 31Standard and Limit .................................................. 31

ENGINE COOLANT CAPACITY (APPROXI-MATE) .................................................................. 31RADIATOR .......................................................... 31THERMOSTAT .................................................... 31

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PRECAUTIONS


PRECAUTIONS PFP:00001

Precautions for Supplemental Restraint System (SRS) “AIR BAG” and “SEAT BELT PRE-TENSIONER” ABS004RH

The Supplemental Restraint System such as “AIR BAG” and “SEAT BELT PRE-TENSIONER”, used alongwith a front seat belt, helps to reduce the risk or severity of injury to the driver and front passenger for certaintypes of collision. This system includes seat belt switch inputs and dual stage front air bag modules. The SRSsystem uses the seat belt switches to determine the front air bag deployment, and may only deploy one frontair bag, depending on the severity of a collision and whether the front occupants are belted or unbelted.Information necessary to service the system safely is included in the SRS and SB section of this Service Man-ual.WARNING:● To avoid rendering the SRS inoperative, which could increase the risk of personal injury or death

in the event of a collision which would result in air bag inflation, all maintenance must be per-formed by an authorized NISSAN/INFINITI dealer.

● Improper maintenance, including incorrect removal and installation of the SRS, can lead to per-sonal injury caused by unintentional activation of the system. For removal of Spiral Cable and AirBag Module, see the SRS section.

● Do not use electrical test equipment on any circuit related to the SRS unless instructed to in thisService Manual. SRS wiring harnesses can be identified by yellow and/or orange harnesses orharness connectors.

Precautions for Liquid Gasket ABS004RI

REMOVAL OF LIQUID GASKET SEALING● After removing mounting bolts and nuts, separate the mating

surface using the seal cutter [SST] and remove old liquid gasketsealing. CAUTION:Be careful not to damage the mating surfaces.

● Tap seal cutter to insert it, and then slide it by tapping on theside as shown in the figure.

● In areas where seal cutter is difficult to use, use a plastic ham-mer to lightly tap the parts, to remove it.CAUTION:If for some unavoidable reason tool such as a screwdriveris used, be careful not to damage the mating surfaces.

LIQUID GASKET APPLICATION PROCEDURE1. Using a scraper, remove old liquid gasket adhering to the liquid

gasket application surface and the mating surface.● Remove liquid gasket completely from the groove of the liquid

gasket application surface, mounting bolts, and bolt holes.2. Wipe the liquid gasket application surface and the mating sur-

face with white gasoline (lighting and heating use) to removeadhering moisture, grease and foreign materials.

PBIC0002E

PBIC0003E

PRECAUTIONS

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3. Attach liquid gasket tube to the tube presser [SST: WS39930000( — )].Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-47, "RECOMMENDED CHEMICAL PRODUCTS ANDSEALANTS" .

4. Apply liquid gasket without breaks to the specified location withthe specified dimensions.● If there is a groove for the liquid gasket application, apply liq-

uid gasket to the groove.

● As for the bolt holes, normally apply liquid gasket inside theholes. Occasionally, it should be applied outside the holes.Make sure to read the text of service manual.

● Within five minutes of liquid gasket application, install the mat-ing component.

● If liquid gasket protrudes, wipe it off immediately.● Do not retighten after the installation.● After 30 minutes or more have passed from the installation, fill

engine oil and engine coolant.CAUTION:If there are specific instructions in this manual, observe them.

EMA0622D

SEM159F

CO-4

PREPARATION


PREPARATION PFP:00002

Special Service Tools ABS0035A

The actual shapes of Kent-Moore tools may from those of special service tools illustrated here.

Commercial Service Tools ABS0035B

Tool number(Kent-Moore No.)Tool name

Description

EG17650301(J33984-A)Radiator cap tester adapter

Adapting radiator cap tester to radiator cap and radiator filler necka: 28 (1.10) dia.b: 31.4 (1.236) dia.c: 41.3 (1.626) dia.Unit: mm (in)

KV99103510( — )Radiator plate pliers A

Installing radiator upper and lower tanks

KV99103520( — )Radiator plate pliers B

Removing radiator upper and lower tanks

WS39930000( — )Tube pressure

Pressing the tube of liquid gasket

S-NT564

S-NT224

S-NT225

S-NT052

Tool name Description

Power tool Loosening nuts and bolts

Radiator cap tester Checking radiator and radiator cap

PBIC0190E

PBIC1982E

OVERHEATING CAUSE ANALYSIS

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OVERHEATING CAUSE ANALYSIS PFP:00012

Troubleshooting Chart ABS0035C

Symptom Check items

Cooling sys-tem parts malfunction

Poor heat transfer

Water pump malfunction Worn or loose drive belt

—

Thermostat stuck closed —

Damaged fins

Dust contamination or paper clogging

Physical damage

Clogged radiator cooling tube

Excess foreign material (rust, dirt, sand, etc.)

Reduced air flow

Cooling fan does not oper-ate

Fan assembly —High resistance to fan rota-tion

Damaged fan blades

Damaged radiator shroud — — —

Improper engine coolant mixture ratio

— — —

Poor engine coolant quality — Engine coolant viscosity —

Insufficient engine coolant

Engine coolant leaks

Cooling hoseLoose clamp

Cracked hose

Water pump Poor sealing

Radiator capLoose

Poor sealing

Radiator

O-ring for damage, deterio-ration or improper fitting

Cracked radiator tank

Cracked radiator core

Reservoir tank Cracked reservoir tank

Overflowing reservoir tankExhaust gas leaks into cooling system

Cylinder head deterioration

Cylinder head gasket dete-rioration

CO-6

OVERHEATING CAUSE ANALYSIS


Except cool-ing system parts mal-function

— Overload on engine

Abusive driving

High engine rpm under no load

Driving in low gear for extended time

Driving at extremely high speed

Powertrain system mal-function

—Installed improper size wheels and tires

Dragging brakes

Improper ignition timing

Blocked or restricted air flow

Blocked bumper —

—

Blocked radiator grille

Installed car brassiere

Mud contamination or paper clogging

Blocked radiator —

Blocked condenserBlocked air flow

Installed large fog lamp

Symptom Check items

COOLING SYSTEM

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COOLING SYSTEM PFP:21020

Cooling Circuit ABS0034X

PBIC2692E

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COOLING SYSTEM


System Chart ABS00D9K

PBIC2693E

ENGINE COOLANT

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ENGINE COOLANT PFP:KQ100

Inspection ABS0035F

LEVEL CHECK● Check if the reservoir tank engine coolant level is within the

“MIN” to “MAX” range when the engine is cool.● Adjust the coolant level as necessary.

LEAK CHECK● To check for leaks, apply pressure to the cooling system with the

radiator cap tester (commercial service tool) and the radiatorcap tester adapter [SST].

WARNING:Do not remove radiator cap when the engine is hot. Seriousburns could occur from high pressure engine coolantescaping from the radiator.CAUTION:Higher testing pressure than specified may cause radiatordamage.NOTE:In case that engine coolant decreases, replenish radiator with engine coolant.

● If anything is found, repair or replace damaged parts.

Changing Engine Coolant ABS0035V

WARNING:● To avoid being scalded, do not change engine coolant when the engine is hot.● Wrap a thick cloth around radiator cap and carefully remove radiator cap. First, turn radiator cap a

quarter of a turn to release built-up pressure. Then turn radiator cap all the way.CAUTION:Be careful not to allow engine coolant to contact drive belts.

DRAINING ENGINE COOLANT1. Remove radiator drain hole cap on undercover.2. Open radiator drain plug at the bottom of radiator, and then

remove radiator cap.

SMA412B

Testing pressure

: 157 kPa (1.6 kg/cm2 , 23 psi)

SLC756A

PBIC1204E

CO-10

ENGINE COOLANT


When draining all of engine coolant in the system, open water drain plugs on cylinder block. Referto EM-114, "DISASSEMBLY" .

3. Remove reservoir tank as necessary, and drain engine coolant and clean reservoir tank before installing.4. Check drained engine coolant for contaminants such as rust, corrosion or discoloration.

If contaminated, flush the engine cooling system. Refer to CO-11, "FLUSHING COOLING SYSTEM" .

REFILLING ENGINE COOLANTNOTE:When engine coolant is drained from radiator only, step 3, 4 and 6 are unnecessary.1. Install reservoir tank if removed, and radiator drain plug.

CAUTION:Be sure to clean drain plug and install with new O-ring.

If water drain plug on cylinder block are removed, close and tighten them. Refer to EM-119,"ASSEMBLY" .

2. Make sure that each hose clamp has been firmly tightened.3. Remove air duct assembly. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .4. Disconnect heater hose (right side of vehicle) at the position in

the figure.● Enhance heater hose as high as possible.

5. Fill radiator, and reservoir tank if removed, to specified level.● Pour engine coolant through engine coolant filler neck

slowly of less than 2 (2-1/8 US qt, 1-3/4 lmp qt) a minuteto allow air in system to escape.

● Use Genuine Nissan Long Life Antifreeze/Coolant orequivalent mixed with water (distilled or demineralized).Refer to MA-10, "RECOMMENDED FLUIDS AND LUBRI-CANTS" .

PBIC1205E

Radiator drain plug:

: 0.78 - 1.56 N·m (0.08 - 0.15 kg-m, 7 - 13 in-lb)

PBIC2847E

Engine coolant capacity(With reservoir tank at “MAX” level)

: Approximately 9.6 (10-1/8 US qt, 8-1/2 lmp qt)SMA182B

ENGINE COOLANT

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● When engine coolant overflows disconnected heater hose, connect heater hose, and continue filling theengine coolant, if heater hose is disconnected.

6. Install air duct assembly. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .7. Install radiator cap.8. Warm up until opening thermostat. Standard for warming-up time is approximately 10 minutes at 3000

rpm.● Make sure thermostat opening condition by touching radiator hose (lower) to see a flow of warm water.CAUTION:Watch water temperature gauge so as not to overheat engine.

9. Stop the engine and cool down to less than approximately 50°C (122°F).● Cool down using fan to reduce the time.● If necessary, refill radiator up to filler neck with engine coolant.

10. Refill reservoir tank to “MAX” level line with engine coolant.11. Repeat steps 5 through 9 two or more times with radiator cap installed until engine coolant level no longer

drops. 12. Check cooling system for leaks with engine running.13. Warm up the engine, and check for sound of engine coolant flow while running engine from idle up to

3,000 rpm with heater temperature controller set at several position between “COOL” and “WARM”.● Sound may be noticeable at heater unit.

14. Repeat step 13 three times.15. If sound is heard, bleed air from cooling system by repeating step 5 through 9 until engine coolant level no

longer drops.

FLUSHING COOLING SYSTEMNOTE:When engine coolant is drained from radiator only, step 2, 3 and 5 are unnecessary.1. Install reservoir tank if removed, and radiator drain plug.

If water drain plug on cylinder block are removed, close and tighten them. Refer to EM-119,"ASSEMBLY" .

2. Remove air duct assembly. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .3. Disconnect heater hose (right side of vehicle) at the position in

the figure.● Enhance heater hose as high as possible.

Reservoir tank engine coolant capacity(At “MAX” level)

: 0.8 (7/8 US qt, 3/4 lmp qt)

SMA412B

Radiator drain plug:

: 0.78 - 1.56 N·m (0.08 - 0.15 kg-m, 7 - 13 in-lb)

PBIC2847E

CO-12

ENGINE COOLANT


4. Fill radiator and reservoir tank with water and install radiator cap.● When engine coolant overflows disconnected heater hose, connect heater hose, and continue filling the

engine coolant, if heater hose is disconnected.5. Install air duct assembly. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .6. Run the engine and warm it up to normal operating temperature.7. Rev the engine two or three times under no-load.8. Stop the engine and wait until it cools down.9. Drain water from the system. Refer to CO-9, "DRAINING ENGINE COOLANT" .10. Repeat steps 1 through 9 until clear water begins to drain from radiator.

RADIATOR

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RADIATOR PFP:21400

Removal and Installation ABS0035H

WARNING:Do not remove radiator cap when engine is hot. Serious burns could occur from high-pressure enginecoolant escaping from radiator. Wrap a thick cloth around the cap. Slowly turn it a quarter of a turn torelease built-up pressure. Carefully remove radiator cap by turning it all the way.

REMOVAL1. Remove undercover.2. Drain engine coolant. Refer to CO-9, "Changing Engine Coolant" .

CAUTION:● Perform this step when the engine is cold.● Do not spill engine coolant on drive belts.

3. Remove air duct (inlet) and radiator cover grills (right and left sides). Refer to EM-16, "AIR CLEANERAND AIR DUCT" .

4. Disconnect harness connector from fan motors, and move harness to aside.5. Disconnect CVT fluid cooler hoses.

● Install plug to avoid leakage of CVT fluid.6. Remove radiator hoses (upper and lower) and reservoir tank hose.

1. Bracket 2. Reservoir tank cap 3. Reservoir tank

4. Bracket 5. Clamp 6. Reservoir tank hose

7. Radiator upper clip 8. Mounting rubber 9. Radiator cap

10. Radiator 11. Mounting rubber 12. Clamp

13. CVT fluid cooler hose 14. Clamp 15. Radiator hose (upper)

16. CVT fluid cooler hose 17. O-ring 18. Drain plug

19. Radiator hose (lower) 20. Radiator cooling fan assembly

PBIC1206E

CO-14

RADIATOR


CAUTION:Be careful not to allow engine coolant to contact drive belts.

7. Remove reservoir tank and bracket.8. Remove battery and battery tray, and move fuse and fusible link block to aside. Refer to SC-4, "BAT-

TERY" .9. Remove radiator upper clips by pulling the tabs outside to

release the lock.Do not pull the tabs outside excessively to prevent it fromdamaging.

10. Remove mounting rubbers (upper) from mounting pins on radiator.11. Lift up and remove radiator and radiator cooling fan assembly.

CAUTION:Do not damage or scratch A/C condenser and radiator core when removing.

12. Remove radiator cooling fan assembly from radiator.

INSTALLATIONNote the following, and install in the reverse order of removal.

Radiator Upper ClipInstall radiator upper clip on radiator core connection as follows:1. Install mounting rubbers (upper) on mounting pins of radiator.

2. Align radiator upper clip with radiator core connection, then insert radiator upper clip straight into radiatorcore connections until a click is heard.

3. After connecting radiator upper clip, use the following method to make sure it is fully connected.● Visually confirm that two radiator upper clips are connected to radiator core connections.● Move radiator upper clip and the radiator forward and backward to make sure they are securely con-

nected.

INSPECTION AFTER INSTALLATION● Check for leaks of engine coolant using the radiator cap tester adapter [SST: EG17650301 (J33984-A)]

and the radiator cap tester (commercial service tool). Refer to CO-9, "LEAK CHECK" .● Start and warm up the engine. Visually make sure that there is no leaks of engine coolant and CVT fluid.

PBIC1216E

PBIC1241E

RADIATOR

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Checking Radiator Cap ABS007ZV

● Check valve seat of radiator cap. – Check if valve seat is swollen to the extent that the edge of the

plunger cannot be seen when watching it vertically from the top.– Check if valve seat has no soil and damage.

● Pull negative-pressure valve to open it, and make sure that itclose completely when released.

– Make sure that there is no dirt or damage on the valve seat ofradiator cap negative-pressure valve.

– Make sure that there are no unusualness in the opening andclosing conditions of negative-pressure valve.

● Check radiator cap relief pressure.

– When connecting radiator cap to the radiator cap tester adapter[SST] and the radiator cap tester (commercial service tool),apply engine coolant to the cap seal surface.

● Replace radiator cap if there is an unusualness related to the above three.CAUTION:When installing radiator cap, thoroughly wipe out the radiator filler neck to remove any waxy residueor foreign material.

Checking Radiator ABS007ZW

Check radiator for mud or clogging. If necessary, clean radiator as follows.● Be careful not to bend or damage radiator fins.● When radiator is cleaned without removal, remove all surrounding parts such as cooling fan, radiator

shroud and horns. Then tape harness and connectors to prevent water from entering.1. Apply water by hose to the back side of the radiator core vertically downward.2. Apply water again to all radiator core surfaces once per minute.3. Stop washing if any stains no longer flow out from radiator.4. Blow air into the back side of radiator core vertically downward.

● Use compressed air lower than 490 kPa (5 kg/cm2 , 71 psi) and keep distance more than 30 cm (11.8in).

5. Blow air again into all the radiator core surfaces once per minute until no water sprays out.

PBIC2816E

SMA967B

Standard:

78 - 98 kPa (0.8 - 1.0 kg/cm2 , 11 - 14 psi)Limit:

59 kPa (0.6 kg/cm2 , 9 psi)

SLC755A

CO-16

RADIATOR (ALUMINUM TYPE)


RADIATOR (ALUMINUM TYPE) PFP:21460

Disassembly and Assembly ABS004RT

PREPARATION1. Attach spacer to tip of the radiator plate pliers A [SST].

Spacer specification: 18 mm (0.71 in) wide × 8.5 mm (0.335 in)long × 1.5 mm (0.059 in) thick.

2. Make sure that when the radiator plate pliers A [SST: KV99103510 ( — )] are closed dimension H′′ isapprox. 7.6 mm (0.299 in).

3. Adjust dimension H′′ with spacer, if necessary.

DISASSEMBLY1. Remove upper and lower tanks with the radiator plate pliers B

[SST].CAUTION:Do not disassemble lower tank and CVT fluid cooler.NOTE:Regard lower tank and CVT fluid cooler as an assembly.

1. Upper tank 2. Sealing rubber 3. Core

4. Lower tank (with CVT fluid cooler)

PBIC2539E

SLC655CB

SLC903-A


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● Grip the crimped edge and bend it upwards so that the radia-tor plate pliers B slips off.CAUTION:Do not bend excessively.

● In areas where the radiator plate pliers B cannot be used, usea screwdriver to bend the edge up.CAUTION:Be careful not to damage tank.

2. Remove sealing rubber.3. Make sure the edge stands straight up.

ASSEMBLY1. Clean contact portion of tank.

SLC893

SLC930

SLC931

SLC932

CO-18



2. Install new sealing rubber while pushing it with fingers.CAUTION:Be careful not to twist sealing rubber.

3. Caulk tank in numerical order as shown in the figure with theradiator plate pliers A [SST].

● Use pliers in the locations where the radiator plate pliers Acannot be used.

SLC917A

SLC904-A

PBIC2076E

SLC897


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4. Make sure that the rim is completely crimped down.

5. Make sure that there is no leakage.Refer to CO-19, "INSPECTION" .

INSPECTION1. Apply pressure with the radiator cap tester adapter [SST] and

the radiator cap tester (commercial service tool).

WARNING:To prevent the risk of hose coming undone while underpressure, securely fasten it down with hose clamp.CAUTION:Attach hose to CVT fluid cooler to seal its inlet and outlet.

2. Check for leakage by soaking radiator in water container withthe testing pressure applied.

Standard height “H” : 8.0 - 8.4 mm (0.315 - 0.331 in)

SLC554A

Testing pressure

: 157 kPa (1.6 kg/cm2 , 23 psi)

SLC933-A

SLC934

CO-20

COOLING FAN


COOLING FAN PFP:21140

Removal and Installation ABS00D9I

REMOVAL1. Drain engine coolant from radiator. Refer to CO-9, "Changing Engine Coolant" .


2. Remove air duct (inlet) and radiator cover grills (right and left sides). Refer to EM-16, "AIR CLEANERAND AIR DUCT" .

3. Disconnect radiator hose (upper) at radiator side. Refer to CO-13, "RADIATOR" .4. Disconnect harness connector from fan motors, and move harness to aside.5. Remove battery and battery tray, and move fuse and fusible link block to aside. Refer to SC-4, "BAT-

TERY" .6. Remove mounting bolts to lift up and remove radiator cooling fan assembly.

CAUTION:Be careful not to damage or scratch on radiator core.

INSTALLATIONInstall in the reverse order of removal.

INSPECTION AFTER INSTALLATIONMake sure that fan motors operate normally.NOTE:Cooling fans are controlled by ECM. For details, refer to EC-463, "DTC P1217 ENGINE OVER TEMPERA-TURE" .

1. Cooling fan (RH) 2. Cooling fan (LH) 3. Fan shroud

4. Fan motor

PBIC2694E

COOLING FAN

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Disassembly and Assembly ABS00D9J

DISASSEMBLY1. Remove cooling fans (RH and LH) from fan motors.2. Remove fan motors from fan shroud.

INSPECTION AFTER DISASSEMBLYCooling FanInspect cooling fan for crack or unusual bend.● If anything is found, replace cooling fan.

ASSEMBLYAssemble in the reverse order of disassembly.CAUTION:Cooling fans and fan motors are different between RH and LH. Be careful not to misassemble them.

CO-22

WATER PUMP


WATER PUMP PFP:21020

Removal and Installation ABS00353

CAUTION:● When removing water pump assembly, be careful not to get engine coolant on drive belt.● Water pump cannot be disassembled and should be replaced as a unit.● After installing water pump, connect hose and clamp securely, then check for leaks using the radi-

ator cap tester (commercial service tool) and the radiator cap tester adapter [SST: EG17650301(J33984-A)].

REMOVAL1. Remove engine cover. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .2. Remove air duct (inlet) and radiator cover grills (right and left sides). Refer to EM-16, "AIR CLEANER

AND AIR DUCT" .3. Remove undercover and splash guard (RH).4. Drain engine coolant from radiator. Refer to CO-9, "Changing Engine Coolant" .


5. Remove drive belts. Refer to EM-13, "DRIVE BELTS" .6. Remove reservoir tank of radiator. Refer to CO-13, "RADIATOR" .7. Remove reservoir tank of power steering oil pump with piping connected, and move it to aside. Refer to

PS-33, "HYDRAULIC LINE" .8. Support oil pan (lower) bottom with transmission jack.9. Remove RH engine mounting insulator and RH engine mounting bracket. Refer to EM-107, "ENGINE

ASSEMBLY" .

1. Water pump 2. Timing chain tensioner (primary) 3. Chain tensioner cover

4. Water drain plug (front) 5. Water pump cover 6. O-ring

7. O-ring

PBIC2695E

WATER PUMP

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10. Remove water drain plug (front) on water pump side of cylinderblock to drain engine coolant from engine inside.

11. Remove chain tensioner cover and water pump cover from front timing chain case.● Use the seal cutter [SST: KV10111100 (J37228)] to cut liquid gasket for removal.

12. Remove idler pulley and bracket. Refer to EM-60, "TIMING CHAIN" .13. Remove timing chain tensioner (primary) as follows:a. Remove lower mounting bolt.

CAUTION:Be careful not to drop mounting bolt inside timing chaincase.

b. Loosen upper mounting bolt slowly, and then turn chain ten-sioner (primary) on the mounting bolt so that plunger is fullyexpanded.NOTE:Even if plunger is fully expanded, it is not dropped from the bodyof timing chain tensioner (primary).

c. Turn crankshaft pulley clockwise so that timing chain on the tim-ing chain tensioner (primary) side is loose.

d. Remove upper mounting bolt, and then remove timing chain ten-sioner (primary).CAUTION:Be careful not to drop mounting bolt inside timing chaincase.

14. Remove water pump as follows:

PBIC2662E

PBIC3575E

PBIC1805E

PBIC3576E

CO-24

WATER PUMP


a. Remove three water pump mounting bolts. Secure a gapbetween water pump gear and timing chain, by turning crank-shaft pulley counterclockwise until timing chain looseness onwater pump sprocket becomes maximum.

b. Screw M8 bolts [pitch: 1.25 mm (0.049 in) length: approx. 50mm (1.97 in)] into water pumps upper and lower mounting boltholes until they reach timing chain case. Then, alternatelytighten each bolt for a half turn, and pull out water pump.CAUTION:● Pull straight out while preventing vane from contacting

socket in installation area.● Remove water pump without causing sprocket to contact

timing chain.c. Remove M8 bolts and O-rings from water pump.

CAUTION:Do not disassemble water pump.

INSPECTION AFTER REMOVAL● Check for badly rusted or corroded water pump body assembly.● Check for rough operation due to excessive end play.● If anything is found, replace water pump.

INSTALLATION1. Install new O-rings to water pump.

● Apply engine oil and engine coolant to O-rings as shown inthe figure.

● Locate O-ring with white paint mark to engine front side.

PBIC1193E

JLC357B

SLC943A

PBIC1397E

WATER PUMP

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2. Install water pump.CAUTION:Do not allow cylinder block to nip O-rings when installingwater pump.● Check that timing chain and water pump sprocket are

engaged.● Insert water pump by tightening mounting bolts alternately

and evenly.

3. Install timing chain tensioner (primary) as follows:a. Turn crankshaft pulley clockwise so that timing chain on the tim-

ing chain tensioner (primary) side is loose.

b. Pull plunger stopper tab up (or turn lever downward) so as toremove plunger stopper tab from the ratchet of plunger.NOTE:Plunger stopper tab and lever are synchronized.

c. Push plunger into the inside of tensioner body.d. Hold plunger in the fully compressed position by engaging

plunger stopper tab with the tip of ratchet.e. To secure lever, insert stopper pin through hole of lever into ten-

sioner body hole.● The lever parts and the tab are synchronized. Therefore, the

plunger will be secured under this condition.NOTE:Figure shows the example of 1.2 mm (0.047 in) diameter thin screwdriver being used as the stopper pin.

f. Install timing chain tensioner (primary).● Remove dust and foreign material completely from backside of timing chain tensioner (primary) and

from installation area of rear timing chain case.

g. Remove stopper pin.

h. Make sure again that timing chain and water pump sprocket are engaged.4. Install chain tensioner cover and water pump cover as follows:

SLC031B

PBIC1805E

PBIC3568E

PBIC3577E

CO-26

WATER PUMP


a. Before installing, remove all traces of old liquid gasket from mat-ing surface of water pump cover and chain tensioner coverusing scraper. Also remove traces of old liquid gasket from themating surface of front timing chain case.

b. Apply a continuous bead of liquid gasket with the tube presser[SST: WS39930000 ( — )] to mating surface of chain ten-sioner cover and water pump cover.Use Genuine RTV Silicone Sealant or equivalent. Refer toGI-47, "RECOMMENDED CHEMICAL PRODUCTS ANDSEALANTS" .CAUTION:Attaching should be done within 5 minutes after coating.

c. Tighten mounting bolts.

5. Install water drain plug (front) on water pump side of cylinder block.● Apply liquid gasket to the thread of water drain plug (front).

Use Genuine RTV Silicone Sealant or equivalent. Refer to GI-47, "RECOMMENDED CHEMICALPRODUCTS AND SEALANTS" .

6. Install in the reverse order of removal after this step.● After starting engine, let idle for three minutes, then rev engine up to 3,000 rpm under no load to

purge air from the high-pressure chamber of chain tensioner. Engine may produce a rattlingnoise. This indicates that air still remains in the chamber and is not a matter of concern.


and the radiator cap tester (commercial service tool). Refer to CO-9, "LEAK CHECK" .● Start and warm up the engine. Visually make sure that there is no leaks of engine coolant.

SLC446B

PBIC2663E

WATER INLET AND THERMOSTAT ASSEMBLY

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WATER INLET AND THERMOSTAT ASSEMBLY PFP:21200

Removal and Installation ABS00354

REMOVAL1. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the

front of cylinder block. Refer to CO-9, "Changing Engine Coolant" and CO-22, "WATER PUMP" .CAUTION:● Perform this step when the engine is cold.● Do not spill engine coolant on drive belts.

2. Remove reservoir tank of radiator, and move it aside.3. Disconnect radiator hose (lower) and oil cooler water hose from water inlet and thermostat assembly.4. Remove water inlet and thermostat assembly.

CAUTION:Do not disassemble water inlet and thermostat assembly.Replace them as a unit, if necessary.

1. Gasket 2. Water inlet and thermostat assembly 3. Radiator hose (lower)

4. Water hose

PBIC2696E

SLC962AB

CO-28

WATER INLET AND THERMOSTAT ASSEMBLY


INSPECTION AFTER REMOVAL1. Check valve seating condition at ordinary room temperatures. It should seat tightly.2. Check valve operation.

● If the malfunctioning condition, when valve seating at ordinaryroom temperature, or measured values are out of the standard,replace water inlet and thermostat assembly.

INSTALLATIONNote the following, and install in the reverse order of removal.● Be careful not to spill engine coolant over engine room. Use rag to absorb engine coolant.



Thermostat Standard

Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8.6 mm / 95°C (0.339 in / 203°F)

Valve closing temperature 77°C (171°F)

SLC949A

WATER OUTLET AND WATER PIPING

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WATER OUTLET AND WATER PIPING PFP:11060

Removal and Installation ABS0035E

REMOVAL1. Remove engine cover. Refer to EM-18, "INTAKE MANIFOLD COLLECTOR" .2. Drain engine coolant from radiator drain plug at the bottom of radiator, and from water drain plug at the

front of cylinder block. Refer to CO-9, "Changing Engine Coolant" and CO-22, "WATER PUMP" .CAUTION:● Perform this step when the engine is cold.● Do not spill engine coolant on drive belts.

3. Remove air duct (inlet), radiator cover grills (right and left sides), air cleaner case (upper) with mass airflow sensor and air duct assembly. Refer to EM-16, "AIR CLEANER AND AIR DUCT" .

4. Remove battery and battery tray. Refer to SC-8, "Removal and Installation" .5. Remove CVT fluid cooler control valve assembly. Refer to CVT-232, "TRANSAXLE ASSEMBLY" .6. Move CVT control cable aside. Refer to CVT-211, "SHIFT CONTROL SYSTEM" .7. Remove radiator hose (upper).8. Remove water hoses and heater hoses.9. Disconnect harness connectors, and move harness to aside.

1. Radiator hose (upper) 2. Washer 3. Engine coolant temperature sensor

4. Heater hose 5. Water outlet 6. Water hose

7. Gasket 8. Water hose 9. Gasket

10. Water connector 11. O-ring 12. Heater pipe

13. Heater hose 14. Water bypass pipe 15. Water hose

PBIC4203E

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WATER OUTLET AND WATER PIPING


10. Remove engine coolant temperature sensor as necessary.CAUTION:Be careful not to damage engine coolant temperature sensor.

11. Remove water outlet, heater pipe, water bypass pipe and water connector.

INSTALLATIONNote the following, and install in the reverse order of removal.● Securely insert each hose, and install clamp at a position where it does not interfere with the pipe bulge.● When inserting water bypass pipe and heater pipe into water connector, apply neutral detergent to O-ring.



SERVICE DATA AND SPECIFICATIONS (SDS)

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SERVICE DATA AND SPECIFICATIONS (SDS) PFP:00100

Standard and Limit ABS00E86

ENGINE COOLANT CAPACITY (APPROXIMATE)Unit: (US qt, Imp qt)

RADIATORUnit: kPa (kg/cm2 , psi)

THERMOSTAT

Engine coolant capacity (With reservoir tank at “MAX” level) 9.6 (10-1/8, 8-1/2)

Reservoir tank engine coolant capacity (At “MAX” level) 0.8 (7/8, 3/4)

Cap relief pressureStandard 78 - 98 (0.8 - 1.0, 11 - 14)

Limit 59 (0.6, 9)

Leakage testing pressure 157 (1.6, 23)

Thermostat Standard

Valve opening temperature 80.5 - 83.5°C (177 - 182°F)

Maximum valve lift 8.6 mm / 95°C (0.339 in / 203°F)

Valve closing temperature 77°C (171°F)

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SERVICE DATA AND SPECIFICATIONS (SDS)


ENGINE COOLING SYSTEM B ENGINE CO A - PDF...

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